6XXX Alloys: Chemical Composition and Heat Treatment

Analysis of the influence of chemical composition, crystallization process and heat treatment on the phase constituents’ morphology, and mechanical properties and crack resistance of 6xxx Al alloys were conducted. The alloys with low Mg and Si content (6063) in the as-cast state are characterized by presence of Si particles and primary intermetallic phases: α-Al8Fe2Si, β-Al5FeSi, β-Mg2Si, and α-Al(FeMn)Si. Higher Mg, Si, and Mn content (6005 and 6082) leads to separation of additional phase particles: Al6Fe, Al6Mn, and Al12(FeMn)Mg3Si6, whereas high Cu content (6061—0.35% and 6066—0.95%, respectively) is responsible for precipitation of additional phase particles: Q-Al5Cu2Mg8Si6 and θ-Al2Cu. It has been established that homogenization results in total dissolution of the θ-Al2Cu and Q-Al5Cu2Mg8Si6 primary phases and partial dissolution of β-Mg2Si. Needle-like and Chinese-script α-Al8Fe2Si and β-Al5FeSi were transformed into spheroidal α-Al(FeMn)Si particles. The maximal consolidation of the 6xxx alloys is a result of precipitation of metastable particles, the transient βʺ, βʹ, and Qʹ/θʹ phases (6061 alloy) with high dispersion. The highest mechanical properties were achieved after holding in the temperature of 565°C/6 h, supersaturated in water, and aging at 175°C/10–20 h (T6). The decohesion process in the presence of tensile stresses in the room temperature proceeds through nucleation, the growth and joining of the voids, as well as the cracking of the primary and secondary large-sized intermetallic phase particles. The increase of deformation temperature up to 300°C causes the changes of the nucleation source and joining of voids—it occurs mainly along the matrix–particle interface.